Module 2: Chemical Process

Diagrams
Outline
 Flow Diagrams
 Block Flow Diagrams (BFD)
 Process Flow Diagrams (PFD)
 Piping and Instrument Diagrams (P&ID)
 Other common diagrams
 3-D plant layout diagrams
3 Levels of Diagram
 Block Flow Diagram (BFD)
 Process Flow Diagram (PFD)
 Piping and Instrumentation Diagram (P&ID) –
often referred to as Mechanical Flow Diagram
Complexity Conceptual
increases understanding
increases
As chemical engineers, we are most familiar
with BFD and PFD.
The Block Flow Diagram (BFD)
 BFD shows overall processing picture of
a chemical complex
 Flow of raw materials and products may be
included on a BFD
 BFD is a superficial view of facility – ChE
information is missing
Definitions of BFD
 Block Flow Process Diagram
 Figure 1.1
 Similar to sketches in material and
energy balances
 Block Flow Plant Diagram
 Figure 1.2
 Gives a general view of a large complex
plant
The Block Flow Process Diagram
The Block Flow Plant Diagram

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Developing a Process

 Target product is 37% formaldehyde in water. Known as

formalin
 Occurs of a silver catalyst at 200 oC and 2 – 3 atm
pressure
 Reaction 1 is the predominant reaction
 Develop a block flow diagram that describes the process
 B.P. Pure formaldehyde = -19.3 oC
B.P. Formalin = 96 oC
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The Process Flow Diagram
 PFD shows all process engineering
information
 Diagram developed in second year design
projects with Dr. Jalama
 Often PFD is drawn on large paper –
textbook breaks down information into 1
diagram and 2 tables
The Process Flow Diagram (cont’d)

 The topology of the process – showing the

connectivity of all the streams and the
equipment
 Example for toluene HDA – Figures 1.3 and
1.5
 Tables 1.2 and 1.4 – list information that
should be on the PFD but cannot fit
 Use appropriate conventions – consistency is
important in communication of process
information
ex. Table 1.2
The Process Flow Diagram (cont’d)

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 The Process Flow Diagram (cont’d)
Table 1.2 : Conventions Used for Identifying Process Equipment
Process Equipment General Format XX-YZZ A/B
XX are the identification letters for the equipment classification
C - Compressor or Turbine
E - Heat Exchanger
H - Fired Heater
P - Pump
R - Reactor
T - Tower
TK - Storage Tank
V - Vessel
Y designates an area within the plant
Supplemental ZZ are the number designation for each item in an equipment class
Information
A/B identifies parallel units or backup units not shown on a PFD
Additional description of equipment given on top of PFD

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Equipment Numbering
 XX-YZZ A/B/…
 XX represents a 1- or 2-letter designation
for the equipment (P = pump)
 Y is the 1 or 2 digit unit number (1-99)
 ZZ designates the equipment number for
the unit (1-99)
 A/B/… represents the presence of spare
equipment
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Equipment Numbering (cont’d)
Thus, T-905 is the 5th tower in unit nine
hundred P-301 A/B is the 1st Pump in unit
three hundred plus a spare
 Use unambiguous letters for new equipment
 Ex. Turbine use Tb or J not T (used for tower)
 Replace old vessel V-302 with a new one of
different design - use V-319 (e.g.) not V-302 –
since it may be confused with original V-302
Stream Numbering and
Drawing
 Number streams from left to right as
much as possible
 Horizontal lines are dominant

yes no no
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Stream Numbering and
Drawing (cont’d)
 Add arrows for
 Change in direction
 Inlet of equipment
 Utility streams should use convention
given in Table 1.3, lps, cw, fg, etc.

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Stream Information
 Since diagrams are small, not much
stream information can be included
 Include important data – around
reactors and towers, etc.
 Flags are used – see toluene HDA
diagram
 Full stream data, as indicated in Table
1.4, are included in a separate flow
summary table – see Table 1.5
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Stream Information - Flags

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The Process Flow Diagram (cont’d)
Table 1.4: Information in a Flow Summary
Essential Information
Stream Number
Temperature (°C)
Pressure (bar)
Vapor Fraction
Total Mass Flow Rate (kg/h)
Total Mole Flow Rate (kmol/h)
Individual Component Flow Rates (kmol/h)
Optional Information
Component Mole Fractions
Component Mass Fractions
Individual Component Flow Rates (kg/h)
Volumetric Flow Rates (m3/h)
Significant Physical Properties
Density
Viscosity
Other
Thermodynamic Data
Heat Capacity
Stream Enthalpy
K-values
Stream Name

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The Process Flow Diagram (cont’d)
A Portion of Table 1.5
Stream Number 1 2 3 4 5 6 7 8 9 10

Temperature (°C) 25 59 25 225 41 600 41 38 654 90

Pressure (bar) 1.90 25.8 25.5 25.2 25.5 25.0 25.5 23.9 24.0 2.6

Vapor Fraction 0.0 0.0 1.00 1.0 1.0 1.0 1.0 1.0 1.0 0.0

Mass Flow (tonne/h) 10.0 13.3 0.82 20.5 6.41 20.5 0.36 9.2 20.9 11.6

Mole Flow (kmol/h) 108.7 144.2 301.0 1204.4 758.8 1204.4 42.6 1100.8 1247.0 142.2

Component Mole Flow

(kmol/h)

Hydrogen 0.0 0.0 286.0 735.4 449.4 735.4 25.2 651.9 652.6 0.02

Methane 0.0 0.0 15.0 317.3 302.2 317.3 16.95 438.3 442.3 0.88

Benzene 0.0 1.0 0.0 7.6 6.6 7.6 0.37 9.55 116.0 106.3

Toluene 108.7 143.2 0.0 144.0 0.7 144.0 0.04 1.05 36.0 35.0

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Basic Control Loops
 Often the basic control loops (those
involving maintaining material balance
and reactor controls) are included on
the PFD; instrumentation and other
control loops are not shown
Basic Control Loops

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Equipment Information
 Equipment are identified by number
and a label (name) positioned above
the equipment on the PFD
 Basic data such as size and key data
are included in a separate table
(Equipment Summary Table) Table 1.7
(and Table 1.6) in TBWS
Equipment Information
A Section of Table 1.7: Equipment Summary
Vessel V-101 V-102
Temperature (ºC) 55 38
Pressure (bar) 2.0 24
Orientation Horizontal Vertical
MOC CS CS
Size
Height/Length 5.9 3.5
(m)
Diameter (m) 1.9 1.1
Internals s.p. (splash plate)
PFD Summary
 PFD, Equipment Summary Table, and
Flow Summary Table represent a “true”
PFD
 This information is sufficient for a
preliminary estimation of capital
investment (Chapter 5) and cost of
manufacture (Chapter 6) to be made.

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The Piping and Instrument
Diagram(P&ID)
P&ID – Construction Bible
 Contains: plant construction information
(piping, process, instrumentation, and
other diagrams)
 P&ID information is explained in Tables
1.8 and 1.9
 Conventions for instrumentation are
shown in Figure 1.10
 P&ID

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Look at V-102 on P&ID
V-102 contains an LE (Level Element)
 LE senses liquid level in separator and
adjusts flow rate leaving
 LE opens and closes a valve depending
on liquid level
 LE and valve represent a feedback

control loop
Other Common Diagrams
 Plot Plans – plan or map drawn looking
down on plant (drawn to scale with all
major equipment identified)
 Elevation Diagrams – show view from
side and give information about
equipments distance from ground
Other Common Diagrams

Section of Plot Plan Section of Elevation Diagram

Other Common Diagrams (cont’d)

 Piping Isometrics – show piping in 3-

dimensions
 Vessel Sketches – show key dimensions
of equipment and locations of inlet and
outlet nozzles etc.
Scale Models and Virtual Plants

 25 years ago physical models were used for

review
 Now virtual or electronic models are
generated using software (3-d plant
diagrams)
 Purpose of Models – catch errors such as
 Piping clashes
 Misaligned piping
 Equipment not easily accessed
 Sample points not easily reached by operators
3-D Plant
Diagrams
 Summary
 The three principal diagrams (BFD, PFD, and P&ID)
are used to convey increasingly specific technical
information about a process.
 Important to adhere to common standards for
these diagrams in order to avoid confusion
 Information on equipment layout is most clearly
conveyed through a 3-D plant layout diagram.
1. List all process equipment;
2. How many control loops are there in
the P&ID? List all control loops;
3. List all pressure indicators;
4. List all temperature indicators;
5. List all level indicators;
6. Identify all alarms in the P&ID;
7. How many control valves are in the
 The following procedure can be used when
drawing up preliminary P and I diagrams:
 1. Identify and draw in those control loops
that are obviously needed for steady plant
 operation, such as:
 (a) level controls,
 (b) flow controls,
 (c) pressure controls,